U.S. patent application number 17/417092 was filed with the patent office on 2022-03-17 for apparatus, system and method of combining additive manufacturing print types.
This patent application is currently assigned to JABIL INC.. The applicant listed for this patent is JABIL INC.. Invention is credited to Luke Rodgers.
Application Number | 20220080655 17/417092 |
Document ID | / |
Family ID | |
Filed Date | 2022-03-17 |
United States Patent
Application |
20220080655 |
Kind Code |
A1 |
Rodgers; Luke |
March 17, 2022 |
APPARATUS, SYSTEM AND METHOD OF COMBINING ADDITIVE MANUFACTURING
PRINT TYPES
Abstract
An apparatus, system and method of additive manufacturing. The
apparatus, system and method include at least: a rastering print
head suitable to print an outer contour for the additive
manufacturing print; a secondary print head suitable to print
infrared-actuated print material within the outer counter; and an
infrared actuator, suitable to flow the infrared-actuated print
material within the outer contour.
Inventors: |
Rodgers; Luke; (St.
Petersburg, FL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
JABIL INC. |
St. Petersburg |
FL |
US |
|
|
Assignee: |
JABIL INC.
St. Petersburg
FL
|
Appl. No.: |
17/417092 |
Filed: |
December 19, 2019 |
PCT Filed: |
December 19, 2019 |
PCT NO: |
PCT/US19/67578 |
371 Date: |
June 21, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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62782794 |
Dec 20, 2018 |
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62782729 |
Dec 20, 2018 |
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International
Class: |
B29C 64/209 20060101
B29C064/209; B29C 64/264 20060101 B29C064/264 |
Claims
1. An apparatus for additive manufacturing printing, comprising: a
rastering print head suitable to print an outer contour for the
additive manufacturing print; a secondary print head suitable to
print infrared-actuated print material within the outer counter;
and an infrared actuator, suitable to flow the infrared-actuated
print material within the outer contour.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims benefit of priority to
International Application No. PCT/US2019/067578, filed Dec. 19,
2019, entitled: "Apparatus, System and Method of Combining Additive
Manufacturing Print Types," which claims priority to U.S.
Provisional Application No. 62/782,794, filed Dec. 20, 2018,
entitled: "Apparatus, System and Method of Combining Additive
Manufacturing Print Types," and U.S. Provisional Application No.
62/782,729, filed Dec. 20, 2018, entitled: Apparatus, System and
Method of Heat Filtering for Additive Manufacturing," the
entireties of which is incorporated herein by reference as if set
forth in its entireties.
BACKGROUND
Field of the Disclosure
[0002] The present disclosure relates to additive manufacturing,
and, more specifically, to an apparatus, system and method of
combining additive manufacturing print types.
Description of the Background
[0003] Three-dimensional (3D) printing is any of various processes
in which material is joined or solidified under computer control to
create a three-dimensional object. The 3D print material is "added"
onto a base, such as in the form of added liquid molecules or
layers of powder grain or melted feed material, and upon successive
fusion of the print material to the base, the 3D object is formed.
3D printing is thus a subset of additive manufacturing (AM).
[0004] A 3D printed object may be of almost any shape or geometry,
and typically the computer control that oversees the creation of
the 3D object executes from a digital data model or similar
additive manufacturing file (AMF) file, i.e., a "print plan".
Usually this AMF is executed on a layer-by-layer basis, and may
include control of other hardware used to form the layers, such as
lasers or heat sources.
[0005] There are many different technologies that are used to
execute the AMF. Exemplary technologies may include: fused
deposition modeling (FDM); stereolithography (SLA); digital light
processing (DLP); selective laser sintering (SLS); selective laser
melting (SLM); high speed sintering (HSS); inkjet print and/or
particle jetting manufacturing (IPM); laminated object
manufacturing (LOM); and electronic beam melting (EBM).
[0006] Some of the foregoing methods melt or soften the print
material to produce the print layers. For example, in FDM, the 3D
object is produced by extruding small beads or streams of material
which harden to form layers. A filament of thermoplastic, wire, or
other material is fed into an extrusion nozzle head, which
typically heats the material and turns the flow on and off.
[0007] Other methods, such as laser or similar beam-based or
sintering techniques, may heat or otherwise activate the print
material, such as a print powder, for the purpose of fusing the
powder granules into layers. For example, such methods may melt the
powder using a high-energy laser to create fully dense materials
that may have mechanical properties similar to those of
conventional manufacturing methods. SLS, for example, uses a laser
to solidify and bond grains of plastic, or composite materials into
layers to produce the 3D object. The laser traces the pattern of
each layer slice into the bed of powder, the bed then lowers, and
another layer is traced and bonded on top of the previous.
[0008] In contrast, other similar methods, such as IPM, may create
the 3D object one layer at a time by spreading a layer of powder,
and printing a binder in the cross-section of the 3D object. This
binder may be printed using an inkjet-like process.
[0009] By way of further example, and as will be appreciated by the
skilled artisan, high speed centering (HSS) employs part formation
through the use of heating lamps, such as infrared (IR) lamps. More
specifically, a part for production is, virtually-speaking,
"sliced" into layers in the print plan, as discussed throughout,
and these virtual layers then become actual layers upon application
of the IR by the print process to the treated areas of a print
bed.
[0010] That is, HSS typically occurs using a "bed" of powdered
print material. The print plan may select one or more locations
within the powder bed that will serve as part generation locations.
Each part layer is "printed" onto the part generation pattern in
the powder bed using a heat-absorbing ink. In a typical process, a
broadband IR lamp then delivers heat across the entire print bed.
This heat is absorbed by the heat absorbing ink, thereby forming a
part layer having only those shaped characteristics indicated by
the pattern of the ink placed upon the powder bed, as referenced
above.
[0011] The foregoing process then repeats, layer by layer, until
the completed part is formed. The HSS process accordingly allows
for highly refined designs that may allow for internal movement and
similar interactions, even between internal aspects of a given
part. Moreover, to allow for such refined patterning, an anti-heat
agent, such as water, may also be placed at selected locations
about the print boundaries for a given layer pattern, so as to
prevent undesired absorption of heat by those layers and a
consequent malformation of the part.
[0012] In accordance with the foregoing, part characteristics in
HSS may be varied layer by layer, or even within layers, such as
based on the inks used and/or the level of heat applied. Yet
further, an entire bed may be used to create individual layer
patterns for many parts with each single pass of the IR lamp across
the print powder bed.
SUMMARY
[0013] The embodiments are and include at least an apparatus,
system and method of additive manufacturing. The apparatus, system
and method include at least: a rastering print head suitable to
print an outer contour for the additive manufacturing print; a
secondary print head suitable to print infrared-actuated print
material within the outer counter; and an infrared actuator,
suitable to flow the infrared-actuated print material within the
outer contour.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The disclosed non-limiting embodiments are discussed in
relation to the drawings appended hereto and forming part hereof,
wherein like numerals indicate like elements, and in which:
[0015] FIG. 1 is an illustration of a print system;
[0016] FIG. 2 is an illustration of a print system; and
[0017] FIG. 3 illustrates an exemplary computing system.
DETAILED DESCRIPTION
[0018] The figures and descriptions provided herein may have been
simplified to illustrate aspects that are relevant for a clear
understanding of the herein described apparatuses, systems, and
methods, while eliminating, for the purpose of clarity, other
aspects that may be found in typical similar devices, systems, and
methods. Those of ordinary skill may thus recognize that other
elements and/or operations may be desirable and/or necessary to
implement the devices, systems, and methods described herein. But
because such elements and operations are known in the art, and
because they do not facilitate a better understanding of the
present disclosure, for the sake of brevity a discussion of such
elements and operations may not be provided herein. However, the
present disclosure is deemed to nevertheless include all such
elements, variations, and modifications to the described aspects
that would be known to those of ordinary skill in the art.
[0019] Embodiments are provided throughout so that this disclosure
is sufficiently thorough and fully conveys the scope of the
disclosed embodiments to those who are skilled in the art. Numerous
specific details are set forth, such as examples of specific
components, devices, and methods, to provide a thorough
understanding of embodiments of the present disclosure.
Nevertheless, it will be apparent to those skilled in the art that
certain specific disclosed details need not be employed, and that
embodiments may be embodied in different forms. As such, the
embodiments should not be construed to limit the scope of the
disclosure. As referenced above, in some embodiments, well-known
processes, well-known device structures, and well-known
technologies may not be described in detail.
[0020] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting. For
example, as used herein, the singular forms "a", "an" and "the" may
be intended to include the plural forms as well, unless the context
clearly indicates otherwise. The terms "comprises," "comprising,"
"including," and "having," are inclusive and therefore specify the
presence of stated features, integers, steps, operations, elements,
and/or components, but do not preclude the presence or addition of
one or more other features, integers, steps, operations, elements,
components, and/or groups thereof. The steps, processes, and
operations described herein are not to be construed as necessarily
requiring their respective performance in the particular order
discussed or illustrated, unless specifically identified as a
preferred or required order of performance. It is also to be
understood that additional or alternative steps may be employed, in
place of or in conjunction with the disclosed aspects.
[0021] When an element or layer is referred to as being "on",
"engaged to", "connected to" or "coupled to" another element or
layer, it may be directly on, engaged, connected or coupled to the
other element or layer, or intervening elements or layers may be
present, unless clearly indicated otherwise. In contrast, when an
element is referred to as being "directly on," "directly engaged
to", "directly connected to" or "directly coupled to" another
element or layer, there may be no intervening elements or layers
present. Other words used to describe the relationship between
elements should be interpreted in a like fashion (e.g., "between"
versus "directly between," "adjacent" versus "directly adjacent,"
etc.). Further, as used herein the term "and/or" includes any and
all combinations of one or more of the associated listed items.
[0022] Yet further, although the terms first, second, third, etc.
may be used herein to describe various elements, components,
regions, layers and/or sections, these elements, components,
regions, layers and/or sections should not be limited by these
terms. These terms may be only used to distinguish one element,
component, region, layer or section from another element,
component, region, layer or section. Terms such as "first,"
"second," and other numerical terms when used herein do not imply a
sequence or order unless clearly indicated by the context. Thus, a
first element, component, region, layer or section discussed below
could be termed a second element, component, region, layer or
section without departing from the teachings of the
embodiments.
[0023] The disclosed apparatus, system and method provide a print
methodology that combines aspects of FDM and HSS printing. More
specifically, it is typical of FDM printing, as discussed above,
that, to the extent a "filled" part layers to be created, an outer
contour is first laid, and then a plurality of print beads are
rastered within the outer contour. This is illustrated with respect
to FIG. 1.
[0024] As shown in the FDM print 100 of FIG. 1, an outer contour
print bead 102 is provided, and a plurality of inter-bead raster
runs 104a, b, c, d, are abutted against one another within the
outer contour for a given print layer. As shown, this type of FDM
print is typically subjected to edge gaps 106 between raster runs
104a, b, c, d, and along the outer contour 102, and undesirably
large gaps 110 between rastered runs 104a, b, c, d, particularly
adjacent the turnaround point for the FDM print head.
Unfortunately, the referenced edge gaps 106, and turnaround gaps
and intra-run gaps 110, form weak spots within the formed part.
These weakened spots may lead to cracking, breakage, or part
malformation and can also lead to lower than desired physical
properties such as reduced elongation at break, strength, and
modulus.
[0025] Consequently and as illustrated in FIG. 2, the disclosed
print system may use two printer types, namely an FDM outer contour
print head 202, and a printer 204 for IR-actuated material. Of
note, the IR printer as used herein references any printer type for
which the print material 206 may be heated and/or actuated by an IR
lamp such that the actuated print material will flow a given
amount. Of note, the flowed IR print material 206 may be subjected
to an IR actuating agent by printer 204, or may simply be formed by
a material that is printed (such as an IR-sensitive FDM material)
by printer 204 and is flowed responsive to a given wavelength or
wavelengths of an IR lamp.
[0026] As further illustrated in FIG. 2, the first FDM print head
202 may provide an outer contour 102 in a manner similar to that
discussed above with respect to FIG. 1. The second print head 204
may provide print material 206 within the outer contour that is
actuated by the IR lamp 210 shown in FIG. 2. Thereby, the IR
responsive material 206 within the outer contour 102 may be
actuated, such as through the use of a dispersed IR-actuated agent
on print material 206 or based on heat responsiveness of the
rastered FDM print material 206. Upon actuation of the
inner-printed material 206, the inner-printed material 206 may
modify its shape, such as by flowing to fill the gaps and/or cracks
referenced above in the discussion of FIG. 1. Thereby, the part
formed in FIG. 2 largely eliminates the edge gap 106 and turnaround
and intra-run gaps 110 discussed above, thereby providing a
stronger, more durable, and/or more functional output part.
[0027] Moreover, the use of an outer contour in the embodiments may
substantially or completely avoid the need for an anti-heat agent
along the outer contour of each part layer. By way of non-limiting
example, water maybe unnecessary for disbursement along the outer
contours of the formed part, at least because the contours of the
part will be physically defined by the printing of the outer
contour discussed herein.
[0028] FIG. 3 depicts an exemplary computing and control system
1100 for use in association with the herein described systems and
methods. Computing system 1100 is capable of executing software,
such as an operating system (OS) and/or one or more computing
applications/algorithms 1190, such as applications applying the
print plan, monitoring, process controls, process monitoring, and
process modifications discussed herein, and may execute such
applications 1190 using data, such as materials and process-related
data, which may be stored 1115 locally or remotely.
[0029] More particularly, the operation of an exemplary computing
system 1100 is controlled primarily by computer readable
instructions, such as instructions stored in a computer readable
storage medium, such as hard disk drive (HDD) 1115, optical disk
(not shown) such as a CD or DVD, solid state drive (not shown) such
as a USB "thumb drive," or the like. Such instructions may be
executed within central processing unit (CPU) 1110 to cause
computing system 1100 to perform the operations discussed
throughout. In many known computer servers, workstations, personal
computers, and the like, CPU 1110 is implemented in an integrated
circuit called a processor.
[0030] It is appreciated that, although exemplary computing system
1100 is shown to comprise a single CPU 1110, such description is
merely illustrative, as computing system 1100 may comprise a
plurality of CPUs 1110. Additionally, computing system 1100 may
exploit the resources of remote CPUs (not shown), for example,
through communications network 1170 or some other data
communications means.
[0031] In operation, CPU 1110 fetches, decodes, and executes
instructions from a computer readable storage medium, such as HDD
1115. Such instructions may be included in software, such as an
operating system (OS), executable programs such as the
aforementioned correlation applications, and the like. Information,
such as computer instructions and other computer readable data, is
transferred between components of computing system 1100 via the
system's main data-transfer path. The main data-transfer path may
use a system bus architecture 1105, although other computer
architectures (not shown) can be used, such as architectures using
serializers and deserializers and crossbar switches to communicate
data between devices over serial communication paths. System bus
1105 may include data lines for sending data, address lines for
sending addresses, and control lines for sending interrupts and for
operating the system bus. Some busses provide bus arbitration that
regulates access to the bus by extension cards, controllers, and
CPU 1110.
[0032] Memory devices coupled to system bus 1105 may include random
access memory (RAM) 1125 and/or read only memory (ROM) 1130. Such
memories include circuitry that allows information to be stored and
retrieved. ROMs 1130 generally contain stored data that cannot be
modified. Data stored in RAM 1125 can be read or changed by CPU
1110 or other hardware devices. Access to RAM 1125 and/or ROM 1130
may be controlled by memory controller 1120. Memory controller 1120
may provide an address translation function that translates virtual
addresses into physical addresses as instructions are executed.
Memory controller 1120 may also provide a memory protection
function that isolates processes within the system and isolates
system processes from user processes. Thus, a program running in
user mode may normally access only memory mapped by its own process
virtual address space; in such instances, the program cannot access
memory within another process' virtual address space unless memory
sharing between the processes has been set up.
[0033] In addition, computing system 1100 may contain peripheral
communications bus 1135, which is responsible for communicating
instructions from CPU 1110 to, and/or receiving data from,
peripherals, such as peripherals 1140, 1145, and 1150, which may
include printers, keyboards, and/or the sensors discussed herein
throughout. An example of a peripheral bus is the Peripheral
Component Interconnect (PCI) bus.
[0034] Display 1160, which is controlled by display controller
1155, may be used to display visual output and/or other
presentations generated by or at the request of computing system
1100, such as in the form of a GUI, responsive to operation of the
aforementioned computing program(s). Such visual output may include
text, graphics, animated graphics, and/or video, for example.
Display 1160 may be implemented with a CRT-based video display, an
LCD or LED-based display, a gas plasma-based flat-panel display, a
touch-panel display, or the like. Display controller 1155 includes
electronic components required to generate a video signal that is
sent to display 1160.
[0035] Further, computing system 1100 may contain network adapter
1165 which may be used to couple computing system 1100 to external
communication network 1170, which may include or provide access to
the Internet, an intranet, an extranet, or the like. Communications
network 1170 may provide user access for computing system 1100 with
means of communicating and transferring software and information
electronically. Additionally, communications network 1170 may
provide for distributed processing, which involves several
computers and the sharing of workloads or cooperative efforts in
performing a task. It is appreciated that the network connections
shown are exemplary and other means of establishing communications
links between computing system 1100 and remote users may be
used.
[0036] Network adaptor 1165 may communicate to and from network
1170 using any available wired or wireless technologies. Such
technologies may include, by way of non-limiting example, cellular,
Wi-Fi, Bluetooth, infrared, or the like.
[0037] It is appreciated that exemplary computing system 1100 is
merely illustrative of a computing environment in which the herein
described systems and methods may operate, and does not limit the
implementation of the herein described systems and methods in
computing environments having differing components and
configurations. That is to say, the inventive concepts described
herein may be implemented in various computing environments using
various components and configurations.
[0038] In the foregoing detailed description, it may be that
various features are grouped together in individual embodiments for
the purpose of brevity in the disclosure. This method of disclosure
is not to be interpreted as reflecting an intention that any
subsequently claimed embodiments require more features than are
expressly recited.
[0039] Further, the descriptions of the disclosure are provided to
enable any person skilled in the art to make or use the disclosed
embodiments. Various modifications to the disclosure will be
readily apparent to those skilled in the art, and the generic
principles defined herein may be applied to other variations
without departing from the spirit or scope of the disclosure. Thus,
the disclosure is not intended to be limited to the examples and
designs described herein, but rather is to be accorded the widest
scope consistent with the principles and novel features disclosed
herein.
* * * * *